U.S. patent number 6,936,211 [Application Number 10/192,050] was granted by the patent office on 2005-08-30 for tampon applicator having outwardly flared rim.
This patent grant is currently assigned to McNeil-PPC, Inc.. Invention is credited to Curt Binner, Gary Vogt.
United States Patent |
6,936,211 |
Binner , et al. |
August 30, 2005 |
Tampon applicator having outwardly flared rim
Abstract
Methods for making a tubular device that has a rim disposed at
one end thereof. In one method, a sleeve having an expandable
profiling surface is inserted into an end of the tubular member,
and the profiling surface is expanded to form a shoulder projecting
outwardly from the tubular member adjacent the end of the tubular
member. The profiling surface is collapsed inwardly away from
tubular member, and a return margin is formed directed inwardly
from the shoulder, distal the tubular member. In another method,
return margin of the tubular device adjacent an end is folded
inwardly and superposed on an inner surface of the tubular device
adjacent the folded margin. A sleeve having an expandable profiling
surface is inserted into the end of the tubular device, and the
profiling surface is expanded to form the rim comprising a shoulder
projecting outwardly from the tubular member and the return margin.
As a result, the fold between the shoulder and the return margin
defines an edge of the tubular member.
Inventors: |
Binner; Curt (Somerset, NJ),
Vogt; Gary (Newtown, PA) |
Assignee: |
McNeil-PPC, Inc. (Skillman,
NJ)
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Family
ID: |
24387393 |
Appl.
No.: |
10/192,050 |
Filed: |
July 10, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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596469 |
Jun 19, 2000 |
6450986 |
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Current U.S.
Class: |
264/295; 264/296;
264/313; 264/318; 264/320; 264/322; 264/334; 264/339; 425/393;
425/403; 425/414; 425/417; 425/438 |
Current CPC
Class: |
A61F
13/2097 (20130101); A61F 13/266 (20130101) |
Current International
Class: |
A61F
13/20 (20060101); A61F 13/26 (20060101); B29C
057/12 (); B29C 057/04 (); B29C 057/06 () |
Field of
Search: |
;264/294,295,296,313,318,320,322,334,339
;425/393,403,414,417,438 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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583288 |
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Oct 1924 |
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FR |
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WO 96/23476 |
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Aug 1996 |
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WO |
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Other References
US. Appl. No. 08/594,485, J&J 1580. .
U.S. Appl. No. 09/375,722, J&J 1834. .
U.S. Appl. No. 09/454,989, J&J, 1733. .
McNeil-PPC, Inc., PCT/US 09/10927..
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Primary Examiner: Colaianni; Michael P.
Assistant Examiner: Poe; Michael I.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
This is a division of U.S. patent application Ser. No. 09/596,469,
now U.S. Pat. No. 6,450,986, filed on Jun. 19, 2000, the full
disclosure of which is incorporated herein by reference.
Claims
What is claimed is:
1. A method of making an applicator device for inserting an object
into a mammalian body cavity from a tubular member having an inner
surface and a rim disposed at one end thereof comprising the steps
of: a) inserting a sleeve having an expandable profiling surface
into an end of the tubular member; b) expanding the profiling
surface wherein the profiling surface deforms the tubular member to
form a shoulder projecting radially outwardly from the tubular
member adjacent the end of the tubular member wherein the shoulder
has an inner surface; c) collapsing the profiling surface inwardly
away from tubular member; and d) forming a return margin directed
inwardly from the shoulder, toward the inner surface thereof, and
distal the tubular member thereby forming the applicator device
having a rim comprising the shoulder and the return margin, whereby
the inner surface of the shoulder extends from the inner surface of
the tubular member.
2. The method of claim 1 wherein the step of forming the return
margin comprises inwardly folding a return margin portion of the
shoulder, the return margin is superposed on the inner surface of
the shoulder, and the fold between the shoulder and the return
margin defines an edge of the tubular member.
3. The method of claim 1 further comprising the step of temporarily
immobilizing the tubular member.
4. The method of claim 1 wherein the step of expanding the
profiling surface comprises expanding the sleeve to result in an
expanded profiling surface.
5. The method of claim 4 wherein the step of expanding the sleeve
comprises drawing a tapered ram into the expandable sleeve wherein
the taper is arranged and configured such that a proximal end
contained within the expandable sleeve is smaller than a distal end
projecting from the expandable sleeve.
6. The method of claim 4 wherein the step of expanding the sleeve
comprises ejecting a tapered ram out of the expandable sleeve
wherein the taper is arranged and configured such that a proximal
end contained within the expandable sleeve is larger than a distal
end projecting from the expandable sleeve.
7. A method of making an applicator device for inserting an object
into a mammalian body cavity from a tubular member having an inner
surface and a rim disposed at one end thereof comprising the steps
of: a) inwardly folding a return margin of the tubular member
adjacent an end; b) superposing the return margin on an inner
surface of the tubular member adjacent the folded margin; c)
inserting a sleeve having an expandable profiling surface into the
end of the tubular member; and d) expanding the profiling surface
wherein the profiling surface deforms the tubular member to form
the rim comprising a shoulder projecting radially outwardly from
the tubular member and a return margin directed inwardly from the
shoulder, toward the inner surface of the shoulder, and distal the
tubular member thereby forming the applicator device, whereby the
fold between the shoulder and the return margin defines an edge of
the tubular member and whereby the inner surface of the shoulder
extends from the inner surface of the tubular member.
8. The method of claim 7 further comprising the step of temporarily
immobilizing the tubular member.
9. The method of claim 7 wherein the step of expanding the
profiling surface comprises expanding the sleeve to result in an
expanded profiling surface.
10. The method of claim 9 wherein the step of expanding the sleeve
comprises drawing a tapered ram into the expandable sleeve wherein
the taper is arranged and configured such that a proximal end
contained within the expandable sleeve is smaller than a distal end
projecting from the expandable sleeve.
11. The method of claim 9 wherein the step of expanding the sleeve
comprises ejecting a tapered ram out of the expandable sleeve
wherein the taper is arranged and configured such that a proximal
end contained within the expandable sleeve is larger than a distal
end projecting from the expandable sleeve.
Description
FIELD OF THE INVENTION
The present invention relates to methods of applying an expandable
sleeve to tubular workpieces to form a rim thereon and to rimmed
tubular devices.
BACKGROUND OF THE INVENTION
Paperboard tampon applicators comprising a pair of telescoping
cylinders are well known in the art. For example, Wiegner et al.,
U.S. Pat. No. 4,412,833; Beastall et al., U.S. Pat. No. 5,087,239;
Hinzmann, U.S. Pat. No. 4,755,164; Huffman, U.S. Pat. No.
4,573,964; Whitehead, U.S. Pat. No. 4,508,531; Neilsen et al., U.S.
Pat. No. 5,683,358; and Iskra et al., U.S. Pat. No. 5,702,553 all
teach various aspects of these applicators.
Tampon applicators, whether paperboard or plastic, generally
incorporate surface features at the rear or gripper end to allow
the user to more or less securely hold the applicator while
ejecting the tampon from the opposite end of the applicator. While
molded plastic applicators can generally have pronounced gripper
ends by nature of their fabrication, the gripper end configuration
of paperboard applicators and applicators formed from other
sheet-like materials is more limited. For example, Wiegner et al.
Leaches a lightly grooved grip; Beastall et al. teaches a series of
more pronounced grooves forming rings in the gripper end; Hinzmann
discloses both a grip area having a reduced diameter and surface
indentations; and Whitehead and Huffman both teach finger grip
areas having substantially reduced diameter. Each of the finger
grips taught in this prior art has a limited ability to prevent
finger slip during ejection of the tampon.
More recent efforts have focused on using spinning techniques to
manufacture outwardly disposed rim features. For example, Neilsen
et al. discloses an apparatus for forming an outwardly projecting,
integral fingergrip ring on a tampon applicator. One member of the
apparatus rotates with respect another to form the curl. Iskra et
al. discloses a method of fabricating paperboard tampon applicators
having a diameter of less than about 25 mm and having an outwardly
rolled finger grip. These techniques are similar and may offer very
pronounced raised features on the tubular tampon applicator
elements. However, both suffer from greatly increased mechanical
complexity as they require simultaneous rotation and linear
movements, the surface friction generated during the process can
damage the surface of the materials, and the spinning techniques
require significant clamping force to resist the rotational forces
applied to the workpiece. Finally, these outwardly rolled products
expose their, usually, unfinished inside surface to view in the
rim. Neilsen et al. also illustrates in inwardly spun rim. This
process fails to provide any raised feature while is suffers from
most of the disadvantages described above. The complexity inherent
in and the high frictional forces generated in the spinning
processes results in higher capital equipment costs and increased
likelihood of relatively high levels of scrap generation. Clearly,
these traits are not desirable in a manufacturing process for
low-cost products such as tampon applicators.
Therefore, what is needed is a robust, simple process for applying
a rim to a tubular workpiece that generates an acceptable, low-cost
product without requiring added heat energy (or dissipation
thereof), and without the high axial loading caused by the
rotational movement.
SUMMARY OF THE INVENTION
The present invention relates to an applicator device for inserting
an object into a mammalian body cavity. The applicator includes a
tubular member having a rim disposed at one end thereof. The rim
has a shoulder projecting outwardly from the tubular member and a
return margin directed inwardly from the shoulder distal the
tubular member. The invention is especially useful in manufacturing
paperboard applicators, such as tampon applicators.
In addition, the invention relates to methods of making a tubular
device that has a rim and is capable of inserting an object into a
mammalian body cavity. In one method, a sleeve having an expandable
profiling surface is inserted into an end of the tubular member,
and the profiling surface is expanded to form a shoulder projecting
outwardly from the tubular member adjacent the end of the tubular
member. The profiling surface is collapsed inwardly away from
tubular member, and a return margin is formed directed inwardly
from the shoulder, distal the tubular member.
In another method, return margin of the tubular device adjacent an
end is folded inwardly and superposed on an inner surface of the
tubular device adjacent the folded margin. A sleeve having an
expandable profiling surface is inserted into the end of the
tubular device, and the profiling surface is expanded to form the
rim comprising a shoulder projecting outwardly from the tubular
member and the return margin. As a result, the fold between the
shoulder and the return margin defines an edge of the tubular
member.
As used herein in the Specification and the Claims, the term
"expand" and variants thereof mean that the device modified by this
term spreads or stretches out; is made greater in size, bulk,
volume, or scope; or is enlarged. Thus, a segmented ring may expand
by the individual segments spreading out and a ring may inflate or
be deformed to acquire a greater outer circumference.
The outwardly flared rim of this invention provides a comfortable,
finished edge to at least one member of an applicator, such as a
tampon applicator. When formed on the plunger of such an applicator
also having a barrel, the rim provides a stop to allow a user to
determine when the contents of the applicator device have been
fully expelled. This feature also prevents the plunger from being
pushed or pulled through the barrel and being left behind in the
body cavity. Finally, the rim provides an aesthetically pleasing
edge to the applicator device.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partially broken-away, perspective view of a tampon
applicator according to the present invention.
FIG. 2 is a perspective view of an alternative tampon applicator
according to the present invention.
FIG. 3 is a cross-section along line 3--3 of FIG. 1.
FIG. 3A is a cross-section along line 3--3 of FIG. 1 showing an
alternative embodiment of the present invention.
FIGS. 4-9 are cross-sections of apparatus used in various positions
during their manipulation in a process according to the present
invention.
FIG. 9A is a cross-section along line 9A--9A of FIG. 9 showing a
segmented expandable sleeve useful in the present invention.
FIGS. 10-16 are cross-sections of apparatus used in various
positions during their manipulation in an alternative process
according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the present invention generally relates to devices having a
tubular member with a rim disposed at one end thereof, the
following detailed description will refer, specifically, to a
tampon applicator, a particularly preferred embodiment. One of
ordinary skill in the art will recognize other uses for this
invention including, without limitation, applicators for other
catamenial devices, such as collection cups, inflatable plugs or
cups, and the like; incontinence devices; suppositories; nasal
packing; and the like.
FIGS. 1 and 2 disclose a tampon applicator 10 according to the
present invention formed of a barrel 12 and a plunger 14. The
barrel 12 has an insertion end 16 and a gripper end 18, and it is
arranged and configured to contain a tampon 20 having a withdrawal
string 22.
The plunger 14 has an insertion end 24 and a gripper end 26
generally directed toward the insertion end 16 and gripper end 18
of the barrel 12, respectively. The insertion end 24 of the plunger
14 is arranged and configured to be slideably introduced into the
gripper end 18 of the barrel 12.
The tampon applicator of the present invention also includes at
least one rim 28 that finishes at least one edge of at least one of
its components. For example, referring to FIGS. 1 and 3, the
plunger 14 has a rim 28 disposed at the edge 30 associated with the
gripper end 26. The rim 28 includes a shoulder 32 and a return
margin 34. Either the return margin 34, itself, or a fold 36
between the shoulder 32 and the margin 34 that defines the edge 30
associated with the gripper end. The return margin 34 begins at the
point or region where the material forming the rim 28 begins to
return toward the interior of the tubular member, such as at point
P in FIG. 3A.
In an alternative embodiment of the present invention illustrated
in FIG. 2, the barrel 12 may also have a rim 40 disposed at the
edge 42 associated with the gripper end 18. The rim 40 on the
barrel 12 includes the features described above for the rim 28 on
the plunger 14, especially with reference to FIG. 3.
In one preferred embodiment of the invention shown in FIG. 3A, the
return margin 34' of the rim 28 provides a radius to the edge 30
associated with the gripper end 26 such as provided when the
shoulder 32 and the return margin 34' together form an S-curve.
This radiused edge 30 thereby provides a more comfortable bearing
surface for a user while pressure is applied to the gripper end 26
of the plunger 14.
Alternatively as shown in FIG. 3, the return margin 34 is
superposed on the inner surface 38 of the shoulder 32. Preferably,
the return margin 34 is superposed on at least about half of the
inner surface 38 of the shoulder 32. Again, the rim 28 provides the
radius to the edge 30 due to the fold 36.
The tampon applicators 10 or other tubular devices of the present
invention can have tube geometries or cross-sections that are
useful to contain the object to be inserted. Often, the shape of
the tampon contained suggests the shape of the barrel 12, but
departures from this general rule may be made. Therefore, the
barrel 12 may take on numerous cross-sectional shapes including,
without limitation, circular, oval, polygonal (e.g., trapezoidal,
rectangular, triangular), and the like. For example, cylindrical
tampons may be contained within rectangular barrels and trapezoidal
tampons (such as those disclosed in Van Iten et al., U.S. Pat. No.
5,350,371) and cup-shaped tampons (such as those disclosed in
Bailey, U.S. Pat. No. 2,330,257) can be contained in a generally
cylindrical barrel. In addition, the barrel 12 can substantially
elongated, curved, or flexible, or it can take on other shapes that
are apparent to one of ordinary skill in the art. The specific
geometry, itself, is not critical to the practice of the present
invention. In addition, the edge of the tubular device (both
finished and unfinished) may be a standard, planar edge coincident
with a plane perpendicular to the longitudinal axis of the tubular
device. However, the edge may also be coincident with a plane
oblique to the longitudinal axis, or it may be recessed as
described in the commonly assigned, copending application of Buzot,
U.S. Ser. No. 09/454,989(herein incorporated by reference).
Preferably, the rim 28 projects outwardly from the tubular member
14 by at least about 0.1 mm, and more preferably, by at least about
1 mm, and most preferably, by at least about 3 mm. This outward
projection is useful to provide a comfortable, finished edge to at
least one member of an applicator, such as a tampon applicator.
When formed on the plunger 14 of such an applicator 10 also having
a barrel 12, the rim 28 provides a stop to allow a user to
determine when the contents of the applicator device 10 have been
fully expelled. This feature also prevents the plunger 14 from
being pushed or pulled through the barrel 12 and being left behind
in the body cavity.
While the specific tube geometry is not critical, in order for the
rim 28 to provide a stop, it must create an interference with at
least part of the barrel 12. This interference can be accomplished
in any numbers of ways. Preferably, the interference is
accomplished by configuring the rim 28 such that at least a portion
of the rim 28 must project beyond an area defined by the inner
dimensions of the barrel 12. For example, in a pair of cylindrical
tubular members, the rim 28 of the plunger 14 should have a maximum
outer diameter that is greater than the minimum inside diameter of
the barrel 12. Alternatively, in a pair of tubular members in which
the plunger is cylindrical and the barrel has a polygonal
cross-section, the rim of the plunger should have a maximum outside
diameter that is greater than the minimum inner dimension of the
barrel passing through a central axis thereof. In yet another
alternative, in which the plunger has a rectangular cross-section
and the barrel is cylindrical, the maximum length of a side of the
rim is greater than a corresponding chord of the circle defined by
the inner diameter of the barrel. The term "diameter" as used in
herein the specification and the claims means a chord passing
through the center of a figure or body; the length of a straight
line through the center of an object
In reference to an applicator 10 comprising a pair of cylindrical
tubular members (barrel 12 and plunger 14), it is preferred that
the rim 28 on the plunger 14 has a maximum outside diameter that is
greater than the minimum inner diameter of the barrel 12. More
preferably, the maximum outside diameter of the rim 28 is targeted
to at least equal to the outside diameter of the barrel 12. This
allows for variability inherent in manufacturing processes to
ensure that an interference will occur between the two members.
The applicator devices of the present invention can be made of
materials generally known to those of ordinary skill in the art.
The applicators may be plastic, such as injection-moldable or
blow-moldable plastic, biodegradable plastic, such as those
disclosed in Dabi et al., U.S. Pat. No. 5,910,520(herein
incorporated by reference), or cardboard. However, the invention is
especially effective with cardboard applicators. The cardboard used
in tampon applicators can be a single layer of cardboard material,
or it can be a plurality of laminated layers to provide multiple
benefits relating to the various layers. Useful cardboard stock for
the formation of the tubular elements include, without limitation,
paperboard, cardboard, cup stock, paper, and the like. The
laminated cardboard material may include a surface layer or coating
of plastic, wax, silicone, and the like, which may be useful to
increase the comfort to the user during insertion and withdrawal.
The plastic coating may include, without limitation, polyolefins
such as polyethylene and polypropylene, polyesters such as
polyethylene terephthalate, polycaprolactone, polyvinyl alcohol,
ethylene-vinyl acetate copolymers, cellophane, and the like.
Preferred tubular element materials include laminated cardboards.
Preferred laminated cardboards include plastic laminated or plastic
coated cardboard materials. These plastic laminated cardboard
materials may include additional layers such as adhesive layers,
tie layers, and the like.
Typical dimensions for the tubular elements useful in tampon
applicators include a length of about 5 to 8 cm, a diameter of
about 8 to 16 mm, and thicknesses of about 0.1 to 0.6 mm.
Preferably, the diameter of the inner tubular element is less than
the diameter of the outer tubular element to allow for a telescopic
arrangement of the inner tubular element within the outer tubular
element as shown in FIG. 1. The applicators can be made by the
following non-limiting processes: spiral winding as disclosed in
U.S. Pat. No. 5,346,468, convolute winding as disclosed in U.S.
Pat. No. 4,508,531, and forming a sheet around a mandrel and then
sealing an overlapped seam as disclosed in U.S. Pat. No.
4,755,164.
The rim 28 of the present invention may be formed by first
expanding the edge 30 to form the shoulder 32 and then tucking or
folding it to form the return margin 34 (the "Expand/Tuck" process
shown in FIGS. 4-9). Alternatively, it may be formed by first
inwardly folding the return margin 34 and then expanding it to form
the shoulder 32 (the "Tuck/Expand" process shown in FIGS. 10-16).
In the Expand/Tuck process, a workpiece, such as a tampon
applicator 10 is placed into a holder 102. The holder 102 is
capable of reciprocating movement to clamp the tampon applicator 10
to substantially immobilize it. The holder 102 preferably
immobilizes both the insertion end 16 (e.g., of the barrel 12) and
the gripper end 26 (e.g., of the plunger 12), and it can accomplish
this by means of a single set of jaws or multiple sets of jaws. In
FIG. 5, a first set of jaws 104, capable of reciprocating movement,
clamps the insertion end 16 and a second set of jaws 106, capable
of reciprocating movement, clamps the gripper end 26. When the
tampon applicator 10 is at least partially immobilized, at least a
portion of a sleeve 108 is inserted axially into the insertion end
16.
In one preferred embodiment, the tampon applicator 10 includes a
barrel 12, a plunger 14, and a tampon 20, and the first set of jaws
104 clamps on the insertion end 16 of the barrel 12. Next, at least
a portion of the sleeve 108 is inserted axially into the gripper
end 26 of the plunger 14 as shown by arrow "A", and a flange 110
projecting radially outwardly from the sleeve 108 contacts the edge
30 of the plunger 14 to ensure that the plunger 14 is fully
inserted into the barrel 12 prior to the movement of the second set
of jaws 106 in to clamp and immobilize the gripper end 26 of the
plunger 14.
Once the sleeve 108 is inserted axially into the immobilized
gripper end 26 of the plunger, a tapered ram 112 is drawn axially
(as shown by arrow "B") into the sleeve 108 to cause a profiling
surface 114 located on the sleeve 108 to expand radially in the
direction of arrows "C" toward the inner surface 38 of the plunger
14 as shown in FIG. 6. After contact with the inner surface 38, the
sleeve 108 can continue to expand radially to flare a portion of
the gripper end 26 of the plunger 14 with the profiling surface 114
to form the shoulder 32. This expansion is achieved primarily,
preferably completely, without any relative rotation between the
profiling surface 114 and the plunger 14. As discussed above, this
allows the shoulder 32 to be formed more easily than with a
spinning process.
Referring now to FIG. 7, the tapered ram 110 is expelled axially
from the sleeve 108 which retracts radially away from the shoulder
32, as indicated by arrows "D". This allows the sleeve 108 to again
move axially within the gripper end 26 of the plunger 14. Indeed in
an optional step, the sleeve 108 can move axially as shown by arrow
"E" in FIG. 8 into the gripper end 26 to allow the flange 110,
preferably an edge 116 of the flange 110, to again contact the edge
30 of the plunger 14. This contact tucks the edge 30 into the
shoulder 32, preferably to superpose it on the inner surface 38, to
form the rim 40. As shown in FIG. 9, the sleeve 108 can be
withdrawn axially from the gripper end 26, and the jaws of the
holder can retract to allow the tampon applicator 10 to be removed
from the holder 102. If the return margin 34 is not required to be
folded completely to a superposed position, the second set of jaws
106 may be modified to form an annular ring having, e.g., a
semicircular cross-section.
The apparatus used in the Expand/Tuck process includes the holder
102 formed of first and second jaws 104, 106. These jaws 104, 106
may be portions of the same tooling, or they may be independently
operable as discussed, above. The holder 102 may be considered an
outer set of tooling. In addition, the apparatus includes a sleeve
108 and a tapered ram 110. The sleeve 108 may have a flange 110 and
a profiling surface 114 to form the outwardly flared edge.
Preferably, the flange 110 has a beveled or rounded edge 116 to
provide a biased surface to initiate tucking the return margin 34
into the shoulder 32 to form the rim 40.
In the alternative Tuck/Expand process shown in FIGS. 10-16, a
workpiece, such as a tampon applicator 10 is placed into a holder
202. The holder 202 clamps the tampon applicator 10 to
substantially immobilize it. The holder 202 preferably immobilizes
both the insertion end 16 and the gripper end 18, preferably by
means of multiple sets of jaws. As shown in FIGS. 11 and 12, a
first set of jaws 204 clamps the gripper end 18, and a second set
of jaws 206 clamps the insertion end 16.
The tampon applicator 10 is immobilized in the holder 202 in a
condition that exposes a predetermined length of the gripper end 18
to protrude from the first set of jaws 204 with the holder 202,
tampon applicator 10, and a reciprocating set of tooling 208
axially aligned. An outer sleeve 209 of the tooling 208 moves
axially in the direction of arrow "F" to bring a front face 210 of
the outer sleeve 209 into contact with the rear face 212 of the
first set of jaws 204. The inner diameter of the outer sleeve 209
has a diameter that is slightly less than the diameter of the
holder 202, especially of the first set of jaws 204. The front face
210 has a slightly beveled edge 214 to direct the edge 30 of the
gripper end 18 inwards. Thus, as the tooling 208 moves axially
toward the first set of jaws 204, the beveled edge 214 contacts the
edge 30 and curls the return margin 34 radially inwards.
As shown in FIGS. 12 and 13, the tooling 208 has an inner, sleeve
216 and a tapered ram 218. The inner sleeve 216 and ram 218 move
axially (as indicated by arrow "G") into the tampon applicator 10,
and a flange 220 on the tapered ram 218 contacts the return margin
34 to tuck (or fold) it onto the inner surface 38. The ram 218 is
drawn into the inner sleeve 216, and an expandable profiling
surface 222 is forced radially outwards in the direction of arrows
"H" to expand the rearmost portion of the gripper end 18 forming
the shoulder 32 and the rim 28. Finally, the tooling 208 and the
holder 202 release the tampon applicator 10, and the process is
complete. Again, the expansion is achieved primarily, preferably
completely, without any relative rotation between the profiling
surface 222 and the tampon applicator 10.
The apparatus used in the Tuck/Expand process includes the holder
202 formed of first and second jaws 204, 206. These jaws 204, 206
may be portions of the same tooling, or they may be independently
operable as discussed, above. In addition, the apparatus includes a
set of tooling capable of reciprocating movement 208, comprising an
outer sleeve 209, an inner sleeve 216, and a ram 218. The outer
sleeve 209 preferably has a beveled edge 214 on its front face 210.
The tapered ram 218 preferably has a flange 220 at its distal end,
and the inner sleeve 216 preferably has a profiling surface 222 at
its distal end.
The apparatus and processes have been described above with
reference to specific tooling illustrated in the drawing. However,
one of ordinary skill in the art will recognize that the use of
such tooling is not critical and alternatives are available.
For example, expanding the sleeve is preferably achieved by the
interaction of the sleeve and the ram. A ram can have a taper that
is arranged and configured such that a proximal end contained
within the sleeve has a smaller cross-section than a distal end
projecting from the sleeve. In contrast, the taper could be
arranged and configured such that a proximal end contained within
the sleeve has a larger cross-section than a distal end projecting
from the sleeve. Thus, a sleeve can be expanded by drawing the
former tapered ram into the sleeve or it could be expanded by
withdrawing the latter tapered ram out of the sleeve. Indeed, the
sleeve and the expandable profiling surface could be an expanding,
segmented collet as illustrated in FIG. 9A wherein the segmented,
or split, profiling surface 114 forms a portion of the split sleeve
108. The flange 110 also comprises six segments 110a-110f, as
illustrated.
Alternatively, the ram could be substantially cylindrical while the
sleeve could be tapered in either direction. In yet another
arrangement, the sleeve or features on the sleeve, such as the
profiling surface and/or the flange may be extendable by means of
hydraulics or air pressure.
While the preceding description has focused on an expandable,
generally split, sleeve 108, the expandable profiling surface can
also be achieved through technologies such as air mandrel
technology and are like. In addition, the profiling surface may be
segmented, as illustrated in FIG. 9A, it also may be formed of a
resilient and/or elastic material, such as a deformable, continuous
elastomeric o-ring that may be placed upon an expandable sleeve,
even a split sleeve, or another deforming device, e.g., a linear
compression device. Still other methods of extending the
appropriate features on the tooling will be recognized by the
ordinarily skilled artisan.
The specification above is presented to aid in the complete and
non-limiting understanding of the invention disclosed herein. Since
many variations and embodiments of the invention can be made
without departing from its spirit and scope, the invention resides
in the claims hereinafter appended.
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